Deposited latex articles



July 10, 1962 H. J. BARTH DEPosITED LATEX ARTICLES 5 Sheets-Sheet 1Filed Sept. 9, 1958 INV ENTOR HARRY J. BARTH ATTORNEY July 10, 1962 H.J. BARTH DEPOSITED LATEX ARTICLES 3 Sheets-Sheet 2 Filed sept. 9, 195e Rm m m HARRY J. BARTH ATTORNEY July 10, 1962 H. J. BARTH DEPosITED LATEXARTICLES 3 Sheets-Sheet 3 Filed Sept. 9, 1958 INVENTOR HARRY J. BARTHATTORNEY 3,643,311 DEPGSITED LATEX ARTICLES Harry J. Barth, Dover, Del.,assigner to International Latex Corporation, Dover, Del., a corporationof Dela- Wre Fried sept. 9, 195s, ser. No. 760,021 4 claims. (ci. 12s-521) This invention relates to deposited latex articles and methods forforming such articles and, more particularly, to deposited latexarticles having integrally formed pockets in the wall of the article,which pockets may be used to anchor garters, straps and the liketherein, and to the forming of such integral pockets during thefabrication of the deposited latex article.

A major problem encountered in producing serviceable deposited latexarticles, such as girdles or brassieres, of the type which haveaccessories (e.g., garter straps, shoulder straps or other attachments)affixed to the marginal portions thereof, has been the limited abilityof these portions of the deposited latex articles to which theseattachments are joined to withstand the repeated flexing andconcentrated tension to which such portions are subjected by stressingand/or straining the attachments during wearing. Various devices havepreviously been employed to attach such straps to deposited latexarticles, but these involve either complicated methods of manufacture orattachment or employ exposed ends (buttons or tabs) which will interferewith the clothes or the body of the wearer. i

The present invention provides a simple and inexpensive method forforming potential pockets for the anchoring of accessories within thecontines of the wall of a deposited latex article during the formationthereof, and subsequently processing such potential pockets to form openintegral pockets at or along at least one marginal edge of the depositedlatex article. Subsequently anchorage of a support strap or otheraccessory within the pocket can be effected by various fastening orattaching devices or fastening, as by sewing, the strap within thepocket. Articles having such integral pockets have superior service--ability under the stresses occurring during use and superior consumeracceptance, yet are relatively inexpensive to produce. y

In accordance with the present invention, the integral pocket in thewall of the deposited article is formed by preventing adhesion, within asmall selected area, between successive depositions of the latex so asto form a closed pocket or envelope and subsequently cutting or trimmingthe article so as to open the pocket. Adhesion between successivedepositions or layers of latex can be prevented by placing alatex-separating material, shaped generally similarly to the openportion of the final or ultimate pocket but extending a small distancebeyond what becomes the open portion of the pocket, on a deposited latexfilm having only a portion of the ultimate or finished thickness of thedeposited latex article and subsequently depositing thereon additionallatex. Thus, a closed pocket is formed that is potentially an openpocket, the latter being formed when the closed pocket is cut or trimmedto expose or open a portion of the boundary of the closed pocket. Afterinterior of the pocket is accessible, the successive layers of latex oneither side of the latex-separating material can be separated or partedat the plane of the latex-separating material and thus form an openpocket. The latex-separating material may be a single piece of film,such as polyethylene to which latex does not adhere, or it may lbe apiece or pieces of film folded and/or sealed at the edges to form aclosed envelope. In the latter instance, the envelope may be made ofmaterial, such as fabric impregnated with latex, to which latex adheres.Such 3,043,311 Patented July 10, 1962 ice a material has the advantagethat it remains in the pocket to reinforce it or make the inside smooth.When the film is positioned at a desired place on the article (forexample, partially extending over what will be the finished edge of thegarment, in the case of garter or brassiere support attachments) duringdeposition of the latex and the finished dipped article is trimmed alongpredetermined lines to expose generally a portion of the boundary of thepocket, an integral pocket, open at the margin of the article, isformed.

The area or region on one or both sides of the latexseparating materialcan be advantageously reinforced,

such as by a piece of reinforcing fabric capable of becoming impregnatedwith latex during the dipping operation or, as pointed out above, thelatex-separating material itself may incorporate a reinforcing fabric.Thus, a piece of film to which latex does not adhere may be placedbetween a folded piece of fabric to form a reinforcing patch assemblyand the assembly placed on the surface of the wet latex of a partiallydipped article. The wet latex Strikes through or impregnates the fabricnext to it and subsequent dipping (to form the completed article)impregnates the other side of the fabric assembly. Under theseconditions, the reinforcing fabric patch is integrally embedded in thelatex with the piece of film separating the two impregnated pieces offabric thus providing a reinforced pocket within the confines of thewall of the article which can be opened to form an integral pocket.

When an integral pocket is positioned as described above with respect tothe wall of the deposited article, the plane of stress resulting fromtension on the attachment is positioned somewhat centrally with respectto the wall thickness of the article (i.e., since the inside of thepocket has approximately equal wall thicknesses on both sides of it) andany pull on it tends to be transmitted to both adjacent walls withresulting uniform distribution of the stress. This avoids undesirableconcentrations of stress at any point in the region of attachment of astrap to the article so that the region of attachment is capable ofwithstanding more intense flexing and straining without tearing. Also,by reinforcing the inner face of the attachment pocket, there isprovided a structure with improved strength and resistance to tear in ahighly stressed region of the article.

The invention is described in greater detail in connection with thedrawings in which embodiments of the invention, as exemplified ingirdles and brassieres, are illustrated, it being understood that theseembodiments are shown as examples of various forms that the inventionmay take and not by way of limitation thereof.

In-the drawings:

FIGURE 1 is a front View in elevation showing a* deposited latex girdlevhaving integral reinforced pockets for the attachmentof garter straps;

FIGURE 2 is a cross-sectional view taken along the line 2 2 of FIGURE 1showing 'an integral reinforced pocket and attached garter strap; y

FIGURE 3 is a plan View of an assembly used to form a reinforced garterattaching pocket;

FIGURE 4 is a cross-sectional viewA taken along the line 4-4 of FIGURE 3showing the position of the film in the assembly;

FIGURE 5 is a View in elevation of a portion of the girdle beforetrimming showing a potential pocket in the Wall of the girdle and theline along which it will be trimmed;

FIGURE 6 is a cross-sectional View taken along the` FIGURE 8 is across-sectional view taken along the line 8-S of FIGURE 7 showing thereinforced pocket produced in the wall of the girdle by cutting alongthe trim line and removal of the non-adhering film;

FIGURE 9 is a fragmentary view of back and front portions of -adeposited latex brassiere having integral pockets in the wall of thebrassiere with the ends of a shoulder strap mounted therein;

FIGURE 10 is a plan View of a fabric reinforced patch grommet assemblyhaving an attaching grommet shielded by a latex-separating film on eachside thereof;

FIGURE 11 is a cross-sectional view taken along the line 11-11 of FIGUREl0 showing the grommet ernbedded in fabric with a latex-separating filmon each side thereof yand a piece of fabric on the outside of each pieceof film;

FIGURE 12 is a View in elevation of a portion of latex dipped girdlebefore trimming showing the position of grommet assembly;

FIGURE 13 is a cross-sectional view taken along the line 13-13 of FIGURE12 showing the grommet assembly centrally located within the wall of thegirdle;

FIGURE 14 is a view of the portion of the girdle shown in FIGURE 12 withthe bottom edge thereof cut along its trim line; and

FIGURE 15 is a cross-sectional View taken along the line 15-15 of FIGURE14 showing a dual compartment with the gromrnet attachment forming acentral wall therein.

In the drawings, FIGURE 1 illustrates in general a deposited latexgirdle 2li having a front wall 21 and a back wall 22 which form acontinuous body-encircling elastic garment. Positioned in both the front`and back walls of the girdle at the bottom marginal edge 23 thereof arespaced garter tab, strap or ribbon receiving pockets 24 which extendfrom the edge of the girdle vertically upwardly within the connes of thewall thereof (see FIG- URE 2). Each side of pocket 24 has embeddedtherein a fabric reinforcement 25 which forms a reinforced wall defining.a wall of the pocket. The pocket is formed so that the vertical openingtherein lies in the plane passing through approximately the median ofthe wall of the girdle.

Within pocket 24 is positioned the free end of a garter strap or loop26. The free end of the garter loop 26 is held in fixed position bysuitable stitching 27, suc-h as by sewing with nylon thread or any otherthread strong enough tol resist tension and repeated stressing. Otheranchoring or attaching means such as rivets, staples, plastic fasteners,or the like which permanently or releasably anchor or fasten the strapor loop in lthe pocket may be used. Although the wall having the fabricembedded therein is less resilient, it is understood, unless otherwiserefered to hereinafter, that the remainder of the wall of the girdle isof such an elastic character and thickness as to be stretchable and toprovide form fitting control for contouring the human form.

The support pockets 24 are formed within the wall of the deposited latexgirdle during a dipping operation, conducted in a manner similar to themethods described in US. Patent No. 2,360,736, issued to A. N. SpanelOctober 17, 1944. When the deposited latex girdle has, by successivedipping, yacquired a partial wall thickness, such as about 0.005 toAabout 0.015, the dipping operation is interrupted and a reinforcingpatch 28 placed on the partially formed girdle. Reinforcing patch 28(see FIGURES 3 and 4) is formed from two layers of an impregnable fabric25, such .as nylon tricot, rayon, silk, or cotton net and the like, witha rectangular piece of latexseparating film 29 therebetween. It will beappreciated that a woven or knitted fabric or other sheet material whichis foraminous in structure, capable of latex impregnation and providingstrength to the wall of the article may be used to form the patch. Thefabric portion 25 of the patch 28 has an oval body 30 terminating in adownwardly projecting section 31 which gives the patch the appearance ofa projected knob. Sandwiched between the two fabric layers 25 is therectangular shaped film 29 having surface characteristics such that itdoes not adhere to either the wet latex or the latex film after curingthereof.

Film 29 is positioned between the sheets of tricot so that a portion ofthe rectangle extends into the downwardly projecting section 3l. Film 2?may be held in place by spot cementing which aids in holding the patchtogether and facilitates ease of handling of the patch when it isapplied to the wet partially formed latex girdle (see FIGURES 3 and 4).The patch is positioned on the partially formed wet latex girdle inappropriateV positions where the garter straps `are to be located. Whenthe patch is pressed against the wet latex, the latex is ernbedded inthe interstices of the fabric on the surface of the patch. The surfaceof the film,- due to its non-adherent characteristics, resists surfaceadhesion and a wall of the potential pocket is created. Subsequentdipping of the girdle in the bath of latex completes the impregnation ofthe fabric so that the patch assembly is confined within the wall of thedeposited latex girdle thereof as an integral part. This forms, withinthe wall of the girdle, a closed pocket or pouch of the size and shapecorresponding to the size and shape of the film (see FIGURE 6). It willbe appreciated that, by making the fabric portion of the patch larger in`area, the immediate area around the pocket has a two-ply reinforcementtherein which adds strength to the pocket and absorbs la large portionof the strain placed on the portion of the wall of the girdleimmediately surrounding the pocket.

Upon completion of the dipping operation, the girdle y is passed throughla further processing step to effect curing of the latex to give itrubber-like quality. After curing the girdle, it is stripped from theform and the top and bottom of the girdle are finished trimmed alongtheir i trim lines which correspond to the edges of the top and bottom.Trim line 32 in FIGURES 5 and 6 corresponds to the bottom edge 23 ofthegirdle. The trimming operation removes the excess latex which has beenused to assure complete coverage of the girdle generating surf-ace ofthe dipping form. Since the patch 28 is positioned so that projectionsection 31 extends past the trim line, it is simple and easy to open theclosed pocket along a locus positioned on the bottom marginal edge ofthe girdle. Such trimming converts the closed pocket into a rectangular,vertically extending opening or open pocket 24 which is located withinthe wall of the girdle and is reinforced on each side by fabric embeddedin the adjacent deposited latex (see FIGURE 8). This constructionprovides reinforced pockets or pocket-like openings or slots within thewall of the girdle so that support straps, ribbons and other attachmentsmay be associated with the girdle by the simple expedient of sewing orby lche use of other equivalent fastening means to position within theopen pocket the unsightly ends of a garter loop or other supportingmember and thus prevent the wearers clothing and skin from coming intocontact with the edge of the end of the attachment.

As heretofore described, the support pockets of this invention may berformed in a deposited latex brassiere, such -as the brassiere describedin the patents to L. A. Spanel et al. Nos. 2,721,323 and 2,797,415.FIGURE 9 illustrates a fragmentary section of a typical deposited latexbrassiere 40 having `a frontal section 41, spaced breast receiving cups42 and back portions 43 (only one shown) to form a body-encircling band.Positioned along the top and the bottom marginal edges of the brassiereare bands or edgings 44 and 45, respectively, which define the edges ofthe garment and act as reinforcements. Above each breast cup in themarginal edge of the gan ment, is `a rectangularly shaped pocket-likeopening or slot 46. Each side of the pocket is faced with a fabric Ysection 47 embedded in ythe walls forming the pocket in `the mannerheretofore described. The pocket extends downwardly from the top edge ofthe bnassiere separating the -waJl so that the pocket is substantiallycentralized with respect to the median of the wall thickness of thebrassiere. Each back section of the brassiere has a similar rectangularpocket 48 `formed in the same manner yas heretofore described. Pocket 48together with pocket 46 provides means for anchoring the ends of ashoulder strap 49 to the brassiere, one end of the shoulder strap 49being positioned in pocket 46 and the other end in pocket 48. The endsare aiixed in the support pocket in the wall of the brassiere bystitching 50 which pierces the wall of the brassiere and the end of theshoulder strap to form an attachment at this point. In this manner bothshoulder straps are attached to the brassiere in a` manner which resultsin a strong and durable attachment to a relatively thin rubber article.yIt will be appreciated that many types of support attachments may beanchored in support pockets in -brassieres and the like, such aszippers, hook `and eye fastening strips and the like which must beattached to facilitate assembly on the body of the wearer or for comfortof the wearer.

An alternate form of the present invention is illustrated in lFIGURESthrough 15 in which a supporting element is positioned in a pocketformed in Ithe wall of a dipped latex article as heretofore describedfor providing a means for making attachments to the article. In thisarrangement, the supporting element is fixed or mounted in lthe pocketso that it separates the pocket into two compartments so that a strap,ribbon, or other attachment may be securely xed to the supportingelement.

FIGURES 14 and 15 show this type of construction in which a portion of agirdle 51 has formed in the wall thereof a support pocket 52. Centrallylocated in the integral pocket 52 is Ia grommet 53 encased between twopieces of nylon tricot lby heat sealing to `form a unit 54 and positionthe grommet. 'Ihe top and sides of grommet unit 54 extend into the wallof the girdle and are embedded therein so as to firmly anchor a portionof the periphery of the unit in the Wall of the girdle and maintain thegrommet centrally with respect to the pocket. Each side of the pocket 52has a fabric piece 55 embedded therein (see FIGURE l5). Through thegrommet is placed la suitable garter strap (not shown) for supportingthe stockings of the wearer of the girdle.

The integral pocket containing the grommet is formed by interrupting thedipping operation and placing on the deposited latex film a grommetpatch 56. .FIGURES 10 and 11 show a grommet patch assembly in which agrommet 53 is placed between two pieces of nylon tricot and heat sealedto form a unit. The center of the grommet is cut out so that the grommetis completely supported in the tricot. The grommet unit thus formed ispreferably rectangular in form, but, of course, may be in other formsdepending 'on the style desired and the type -of support to be enclosedin the pocket. On each side of the grommet unit 54 is placed a piece oflatexseparating lm 57 smaller in rectangular area than the grommet unitso that there is an exposed vborder around the sides and top edge fofthe grommet unit (see.fFIGURE 1v1). A rectangular piece of nylon tricotfabric 55 which has the same area as the grommet unit is positioned soas to cover the outside surface of each piece of lm in the manner shownin FIGURES 10 and 11. 'Ihis assembly forms the grommet patch`unit whichmay be held toget'her by spot cementing to avoid slipping of the variouspieces forming the unit.

This assembly is pressed against the wet latex to impregnate one side ofthe patch and hold it in position. When used with a girdle, the assemblyis positioned so that a portion of the bottom thereof extends below atrim line S8. Subsequent dipping of the girdle builds up its finishedthickness, embeds the yfabric in the wall of the girdle with the sidesand top border portion of the lilm forming the body of the girdle.

6 grommet assembly 54 and the outside nylon tricot piece becoming anintegral part o-f the wall of the girdle. This embedding of the sidesand the top border provides a firm anchoring of the grommet 'assembly inthe pocket. The ilm positioned on the outside of the grommet assemblyprevents the adherence of the latex thereto so that the grommet assemblyforms a dual compartment with the grommet assembly as a walltherebetweenl (see FIGURE 15).

As heretofore described, trimming along trim line S8 to remove excessdeposited latex, provides an opening of oneend of the pocket so that agarter strap or other similar attachment can be -attamed to the grommetwithin the confines of the wall of the girdle.

It will be appreciated that the pockets forming a part of this inventionmay be formed by the use of any material which will produce an area ofseparation or nonadherence within the wall of the deposited latexgarment when applied between one of the successive dippings thereof.Exemplary tof latex-separating materials are plastic tilms, such .ascellophane, polyethylene, and the like, or metal foils, such as aluminumor tin foil, etc. It has been found that when film is used that a filmthickness of fro-m a few thousandths of an inch to 1/32 provides goodresults and facilitates ease of handling of the patch assembly. However,such thickness can be Varied in accordance with designl requirements,such as the amount of stress imposed on the attachment.

Alternatively, an effective latex-separating material `can' be made byforming a pocket, sealed around the edges,- of or sheet to which latexmay adhere but does not penetrate. IUnder these conditions, thepotential pocket (the interior `of the pocket, sealed against entry oflatex) is formed prior to association with the deposited latex YExemplary of suitable films or sheets are latex impregnated lightfabrics, plastic coated fabric (with the plastic coating on the inside)and the like.

The reinforcing :fabric advantageously is a tricot type fabric woven ofnylon, rayon, silk or other fibers but other woven, knitted orforaminous material, such as marquisettes, bobinettes, Helanca types andthe like which will become impregnated so as to form part of the wallsof the deposited latex may be used, depending on the use and function ofthe pocket.

The position and size of the pockets for attachments and accessoriesdepend on the particular use of the attachment and the article. Forexample, where a grommet is included within the pocket, the size andshape of the pocket will be somewhat larger than a pocket which is tocontain the end of a garter strap sewn in the pocket. If the pocket islocated in the wall of the article 'in such a fashion that it is notclose to a trimming edge, the pocket may be formed by slitting one wallof the article so that an attachment may be associated with the pocket.Both inside and outside attachments can be made at the same location onthe article by slitting through both walls of the pocket so as to forman opening available from both sides of the article, the free ends ofthe attachments Ibeing anchored through both of such openings. Althoughthe latex-separating film used to form the pocket may be removed fromthe pocket after the pocket has been opened, under some conditions itmay be allowed to remain in the pocket to add additional strength.Y

Ihe wall thickness of the deposited article depends upon its intendeduse and, in the case of girdles, a wall thickness of about 0,015 to0.030 is an effective range. It has been found that each Wall of thepocket may vary in thickness, an effective range being 0.003 to about0.025, depending upon the thickness of the garment, the stress to beapplied thereto, and the amount and type of reinforcement. Generally,thickness, size and shape of the pockets will depend upon the nature ofthe attachment made thereto and the stress and strain to be transmittedthrough the Wall of the garment.

Although the present invention has been described with particularitywith reference to preferred embodiments, it will be obvious to thoseskilled in the art, after understanding the invention, that variouschanges and modiications may be therein Without departing from thespirit and scope of the invention, and the appended claims shouldtherefore be interpreted to cover such changes and modications.

Having described my invention, I claim:

1. A deposited latex undergarment adapted to encircle and elastical-lyshape the human torso which comprises a stretchable deposited latex Wallhaving an edge and subject to repeated flexing and stretching duringWear having at least one open pocket positioned Within the contines ofsaid Wall and forming part of an edge of said Wall, said pocket havingclosed sides and an open side, the outside surface of said pocketyform-ing a smooth continuous surface with the surface of the Walladjacent thereto, said pocket having been integrally made duringdeposition of the latex Wall by the formation of a completely closedpocket Within the thickness of the Wall and subsequent cutting of saidclosed'pocket to form an open pocket, the region of the Wall containingsaid open pocket comprising pliable, stretch-resistant reinforcing meansembedded in said wall for resisting stretch occasioned duri-ng -Wear byan accessory secured Within said pocket.

2. The undergarment of claim 1 wherein the reinforcing means is fabric.

3. The method of `forming a deposited latex article with a stretchablewall subject to repeated exing and stretching having at least one openpocket positioned Within the confines of said Wall which comprises firstformi-ng a deposited latex Wall having only a portion of the thicknessof the Wall of the nished article; Vplacing Von the surface of saidlatex Wall adjacent a marginal edge References Cited in the le of thispatent UNITED STATES PATENTS 1,492,953 Bender 1 May 6, 1924 1,523,119Guinzburg Jan. 13, 1925 1,628,195 Rost May 10, 1927 2,365,016 SpanelDec. 12, 1944 2,428,127 Sidnell Sept. 30, 1947 2,440,664 yIrons Apr. 27,1948 2,648,619 Alderfer Aug. 11, 1953 2,726,396 Rosenberg Dec. 13, 1955-2,806,221 Dorsey Sept. 17, 1957 2,813,526 Beebe Nov. 19, 1957 2,898,257Carver Aug. 4, 1959 -1 www

